High temperature conduit having a complex, three-dimensional configuration

ABSTRACT

Molded articles are disclosed having a complex three-dimensional shape. In one embodiment, the molded articles comprise tubular members formed through blow molding that have multiple linear sections separated by curved sections. The curved sections can include multiple angular displacements in multiple planes. The tubular members are molded from a polymer composition containing a high temperature polymer, such as a polymer having a melting point of greater than about 280° C., such as greater than about 290° C. In one embodiment, the tubular member includes at least three angular displacements of from about 60° to about 120°, such as from about 70° to about 110°.

RELATED APPLICATIONS

The present application claims priority to and is based upon Provisional Application Ser. No. 61/446,783, filed Feb. 25, 2011, the entire contents of which are incorporated herein by reference thereto, which claims priority to and is based upon Provisional Application Ser. No. 61/426,409, filed Dec. 22, 2010, the entire contents of which are incorporated herein by reference thereto.

BACKGROUND

Various different high temperature engineering plastics exist that can be used to form different parts and articles. In many applications, those skilled in the art have been attempting to replace conventional metal parts with those made from high temperature polymers. Various high temperature polymers exist that are strong, have excellent chemical resistance, have high rigidity, and are stable at high temperatures. Various advantages and benefits may be obtained if the above polymers can successfully replace metal parts in various embodiments. For example, the plastic parts are lighter, produce less noise, and are more resistant to chemical attack than many metals.

Although low temperature polymers may be molded into many different shapes, problems have been experienced in molding high temperature polymers into complex shapes. For example, problems have been experienced in manipulating high temperature polymers during various molding processes, including during extrusion blow molding.

For instance, when blow molding hollow articles having a complex shape, problems have been experienced in controlling and/or obtaining uniform wall thickness during formation of a parison and in manipulating the parison into a particular shape once the parison is formed. During complex blow molding operations, tubular members are formed that are constantly undergoing shape changes. In one application, for example, a parison is extruded in a downward direction while the polymer composition remains at an elevated temperature. The polymer composition is extruded through an annular opening or die until a desired length of the parison is obtained. The parison should maintain uniform wall thickness while it is being extruded and resist stretching or elongation under only its own weight until a desired length is obtained to begin blow molding. The parison may also be maneuvered for example by a robot during extrusion to change the angular displacement of the tubular form to a specific shape.

The mold closes onto the tubular form once the desired length is attained and a needle is inserted at one end of the closed parison to allow a gas or air to be injected into the tubular form to blow mold the article into its final shape. During the above process, past compositions had a tendency to sag during the process causing changes to the thickness of the parison inadvertently. Sagging is a low shear phenomenon and is affected by the melt strength or melt elasticity of the polymer composition.

Tubular articles capable of functioning in high temperature environments are particularly needed in some industries, such as the automotive industry. For example, car engines and truck engines include various ducts, tubes and exhaust passageways that are designed to convey fluids, such as gases and liquids, to and from the engine. In some embodiments, hot exhaust gases are fed through the above ducts or tubes. In other embodiments, the ducts or tubes may convey lower temperature fluids but are placed in close proximity to engine locations that operate at high temperatures. As engine compartments are becoming more compressed, the above ducts and tubes have had to assume complex three-dimensional shapes in order to fit around the engine and the other parts of the vehicle. In the past, such ducts and tubes have been conventionally made from metals. The present disclosure, however, is directed to engine conduits as described above and other tubular members that are made from high temperature polymers. More particularly, the present disclosure is directed to improved high temperature articles and particularly to tubular members made from high temperature polymers that have a relatively complex shape.

SUMMARY

In general, the present disclosure is directed to tubular articles having a three-dimensional complex shape made from a polymer composition containing a high temperature polymer. The high temperature polymer, for instance, may have a melting point of greater than about 280° C., such as greater than about 290° C., such as even greater than about 300° C. The tubular members made in accordance with the present disclosure are well suited for use in numerous and different applications. The tubular members are well suited for conveying fluids, such as liquids and gases, in a high temperature environment. The high temperature to which the articles are exposed may be due to the temperature of the materials being conveyed through the articles or may be due to the external environment in which the articles are placed.

As described above, tubular members made in accordance with the present disclosure have a complex three-dimensional configuration. For instance, the articles can include several different straight or linear sections separated by various curved sections. The curved sections can form angular displacements that, in some embodiments, can be relatively severe. In fact, in one embodiment, the tubular member may include at least one curved section that comprises multiple angles. For instance, the curved section may include a first angular displacement in the X-Y plane and a second angular displacement in an intersecting plane. In the past, many problems were experienced in attempting to produce complex shaped hollow members as described above from high temperature polymers.

In one embodiment, the present disclosure is directed to an engine conduit for conveying fluids to and from an engine. The engine conduit includes a single piece tubular member having a wall surrounding a hollow passageway. The tubular member is formed from a polymer composition. The polymer composition contains a thermoplastic polymer having a melting point greater than about 280° C. The thermoplastic polymer is present in the polymer composition in an amount of at least about 40% by weight, such as in an amount of greater than about 50% by weight, such as in an amount greater than about 60% by weight.

In accordance with the present disclosure, the tubular member has a three-dimensional configuration including at least three linear sections separated by at least two angular displacements. In one embodiment, the first angular displacement is from about 60° to about 120° and lies in a first plane. The second angular displacement is also from about 60° to about 120°. The second angular displacement, however, is oriented such that it lies in a second plane that intersects with the first plane.

In one embodiment, the tubular member may include at least three angular displacements, such as four angular displacements. The further angular displacements may also be from about 60° to about 120°. In other embodiments, the angular displacements contained in the tubular member may be from about 70° to about 110°, such as from about 80° to about 100°. The angular displacements contained in the tubular member may lie in the same plane but, for most applications, will lie in different planes. In one embodiment, a curved section on the tubular member may include multiple angular displacements that each lie in different planes. For example, a curved section on the tubular member may bend in different directions such that the axis of the tubular member over the curved section lies in the X-Y plane, the X-Z plane, and/or the Y-Z plane.

It is believed that various different thermoplastic polymers may be present in the polymer composition. Such polymers include liquid crystal polymers, polyimide polymers, polyaryletherketone polymers, polyetherimide polymers, fluoropolymers, polyester polymers such as polycyclohexylene dimethyl terephthalate, polyphenylene sulfide polymers, and combinations thereof. In addition to one or more high temperature polymers, the polymer composition may also contain a reinforcing agent, such as a filler or fibers.

In one embodiment, the tubular member is formed from a polymer composition that has a relatively high melt strength. For instance, the polymer composition may be formulated such that at 15° greater than the melting point of the thermoplastic polymer, the polymer composition displays an engineering stress of from about 350 Pa to about 550 Pa at 100% strain. In one embodiment, the above stress versus strain relationship may be determined at 300° C. and at 5 s⁻¹.

Polymer compositions in accordance with the present disclosure are capable of producing hollow tubular members that not only have a complex shape but also have a relatively uniform wall thickness. The wall thickness, for instance, can generally be from about 1 mm to about 5 mm, such as from about 2 mm to about 4 mm. In accordance with the present disclosure, tubular members can be formed such that the wall thickness varies by no more than 50%, such as by no more than about 35%, such as by no more than about 15% over the entire length of the article.

As described above, in one embodiment, a tubular member made in accordance with the present disclosure may be used as an engine conduit. Thus, the present disclosure is also directed to an engine that is in communication with the engine conduit described above. The engine conduit, for instance, may be for conveying cooling fluids, exhaust gases or air to and from the engine.

It should be understood, however, that tubular members made in accordance with the present disclosure may be used in numerous other applications. For instance, the tubular members of the present disclosure are well suited for use in industrial processes, in heating and cooling systems, and the like.

Other features and aspects of the present disclosure are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1 is a perspective view of one embodiment of a shaped article that may be made in accordance with the present disclosure;

FIGS. 2 through 6 illustrate one process for forming the shaped article illustrated in FIG. 1;

FIG. 7 is a graph showing the stress-strain curve for various polymeric compositions described in the present disclosure; and

FIGS. 8-11 are perspective views from different angles of another embodiment of a shaped article made in accordance with the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.

In general, the present disclosure is directed to molded articles having a complex three-dimensional shape. More particularly, the present disclosure is directed to tubular members having a three-dimensional configuration that are made from a polymer composition containing a high temperature polymer. The tubular member, for instance, may comprise a one-piece part that includes multiple linear sections separated by curved sections. The curved sections may include multiple angles that may have sharp angular displacements, such as angular displacements that range from about 60° to about 120°. In addition, the angular displacements may lie in different planes in a manner that causes the linear sections to extend in different directions.

In the past, tubular members as described above were almost exclusively made from metals and lower temperature polymers. Various processing problems were experienced in attempting to mold the parts from high temperature polymers. As will be described in greater detail below, however, polymer compositions may be formulated in accordance with the present disclosure that allow for the compositions to produce tubular members having the above described complex configuration.

The tubular members made in accordance with the present disclosure may be used in many different applications. In one embodiment, for instance, the tubular members may comprise engine conduits that are attached to different parts of an engine, such as a vehicular engine. For example, the engine conduits may comprise exhaust conduits, air ducts, intake air conduits, conduits that extend from an engine to a turbocharger, and the like. Such conduits typically must be capable of withstanding high temperatures due to close proximity to the engine or due to the temperature of the fluids being conveyed through the conduits. Due to space limitations surrounding vehicular engines, conduits that are connected to the engine are required to have greater complexity in size and shape.

In accordance with the present disclosure, the tubular members are made from a polymer composition containing a high temperature polymer. The high temperature polymer, for instance, may comprise a polyarylene sulfide such as a polyphenylene sulfide polymer. In other embodiments, the high temperature polymer may comprise a liquid crystal polymer, a polyimide polymer, a polyaryletherketone polymer such as a polyetheretherketone polymer, a polyetherimide, a fluoropolymer, a polyester polymer such as a polycyclohexylene dimethyl terephthalate polymer, or mixtures thereof. The polymer composition may also contain various other additives and ingredients. In one embodiment, for instance, the polymer composition contains a reinforcing agent, such as a filler, fibers, or mixtures thereof. The polymer composition is formulated so as to have an optimum combination of melt elongation and melt strength properties. In this manner, the high temperature polymer can be manipulated during molding, such as during blow molding, in order to produce a complex shape. For example, in one embodiment, the polymer composition can display an engineering stress of from about 350 kPa to about 550 kPa at 100% strain when tested at a temperature that is 15° C. greater than the melting point of the high temperature thermoplastic polymer contained in the polymer composition.

Referring to FIG. 1, one embodiment of a shaped article made in accordance with the present disclosure is shown. As shown, in this embodiment, the shaped article comprises a tubular member 10. The tubular member 10 can be made according to a blow molding process. As shown, the tubular member 10 extends in multiple directions leading to a relatively complex shape. For instance, before the polymeric composition can solidify, the angular displacements as shown in FIG. 1 are formed into the part. The tubular member 10 includes angular displacement changes at 12, 14 and 16. The tubular member 10 may comprise, for instance, a part that may be used in the exhaust system of a vehicle. During blow molding, a pressurized gas, such as an inert gas, is forced against the interior surface of the tubular member. The compositions of the present disclosure allow the extrusion of the parison with uniform wall thickness and without the polymer creating melt fractures or other imperfections.

One process for making the tubular member 10 as shown in FIG. 1 is illustrated sequentially in FIGS. 2 through 6. Referring to FIG. 2, for instance, the polymeric composition of the present disclosure is first heated and extruded into a parison 20 using a die 22 attached to an extrusion device. As shown, the parison 20 is extruded into a downward direction. When the parison 20 is formed as shown in FIG. 2, the composition used to form the parison must have sufficient melt strength to prevent gravity from undesirably elongating portions of the parison and thereby forming non-uniform wall thicknesses and other imperfections. On the other hand, the melt elongation must also be sufficiently high to allow for processability of the composition. Thus, desirably there is a balance between a high enough melt strength and a high enough melt elongation in order to form the tubular member 10 that can be easily processed while maintaining uniform wall thickness. In other words, the engineering stress must be sufficiently high at a high percent strain to allow for processability of the composition.

As shown in FIG. 2, the parison 20 is extruded adjacent a clamping mechanism 24 which is typically attached to a robotic arm. Also positioned to receive the parison 20 is a molding device 26. In the embodiment illustrated, the molding device 26 includes a first portion 28 and a second portion 30 which together combine to form a three-dimensional mold cavity 32. In the embodiment illustrated, both portions 28 and 30 of the molding device move towards and away from each other. In an alternative embodiment, however, one portion may remain stationary while only the other portion moves.

Referring to FIG. 3, the next step in the process is for the clamping mechanism 24 to engage a top of the parison 20 after the parison 20 has reached a desired length. As shown in FIG. 4, the clamping mechanism then moves the parison into a position so that the parison can interact with the molding device 26. The clamping mechanism 24 can be moved with the aid of a robotic arm.

As can be appreciated, a certain period of time elapses from formation of the parison 20 to clamping and moving the parison 20 into engagement with the molding device 26. During this stage of the process, the melt strength of the polymeric composition should be high enough such that the parison 20 maintains its shape during movement. The polymeric composition should also be capable of remaining in a semi-fluid state and not solidifying too rapidly before blow molding commences.

As shown in FIG. 4, the robotic arm also engages the bottom of the parison 20 with a fluid supply device 34 which is used during blow molding.

Referring to FIG. 5, once the parison 20 has been moved into position, the first portion 28 and the second portion 30 of the molding device 26 move together such that the parison 20 partially extends through the mold cavity 32 as shown in FIG. 4.

As shown in FIG. 5, the first portion 28 includes a top section 40 and the second portion 30 includes a top section 42. In the embodiment illustrated, the bottom sections of the molding device 26 first close leaving the top sections 40 and 42 open. In this manner, the parison 20 can first engage the bottom portion of the molding cavity 32. The clamping device 24 can then robotically move the top of the parison prior to closing the top sections 40 and 42 of the molding device. Once the clamping mechanism is properly located, as shown in FIG. 6, the top sections of the mold close such that the parison extends the entire length of the mold cavity.

Having separately movable top sections as shown in FIGS. 5 and 6 are needed in some molding applications when complex shapes are being formed. By having separate sections of the mold surround the parison at different times allows a robotic arm to continue to manipulate the parison in order to place in the resulting part many angular displacements.

Once the top sections 40 and 42 of the molding device 26 are closed as shown in FIG. 6, a gas, such as an inert gas, is fed into the parsion 20 from the gas supply 34. The gas supplies sufficient pressure against the interior surface of the parison such that the parison conforms to the shape of the mold cavity 32.

After blow molding, the finished shaped article is then removed and used as desired. In one embodiment, cool air can be injected into the molded part for solidifying the polymer prior to removal from the molding device 26.

The polymer composition used to form molded articles in accordance with the present disclosure, such as the tubular member 10 illustrated in FIG. 1 is formulated to have various properties. For example, the polymeric composition of the present disclosure can be fiber reinforced and can have a melt viscosity of greater than 3500 poise when measured at 316° C. and at 400 s⁻¹. For instance, the melt viscosity of the composition can be greater than about 5000 poise, such as greater than about 7500 poise, such as even greater than about 10,000 poise when measured at 316° C. and 400 s⁻¹ (capillary rheometer). For most applications, the melt viscosity is generally less than about 12,500 poise when measured at 316° C. and at 400 s⁻¹.

The composition can also have a relatively high low shear rate storage modulus. The low shear rate storage modulus of the composition, for instance, can generally be greater than about 1500 Pa when measured at 310° C. and at 0.1 rad/s. For example, the low shear rate storage modulus can generally be greater than 1600 Pa, such as greater than 1700 Pa, such as greater than 1800 Pa, such as even greater than 1900 Pa, such as even greater than 2000 Pa when measured at 310° C. and at 0.1 rad/s. The low shear rate storage modulus is generally less than about 6000 Pa, such as less than about 4000 Pa when measured at 310° C. and 0.1 rad/s.

The composition also exhibits certain traits on a stress-strain curve, as shown in FIG. 7.

The synergistic effect of blending the components used to formulate compositions of the present disclosure enables significantly improved control during blow molding for producing products having controlled wall thickness with surface smoothness at relatively high extrusion rates.

Referring to FIGS. 8-11, another embodiment of a tubular member 50 made in accordance with the present disclosure is shown. The tubular member 50 has a three-dimensional complex shape. In particular, the tubular member includes multiple linear sections and curved sections that cause the axis of the tubular member to extend in the X-Y plane, in the X-Z plane, and in the Y-Z plane.

The tubular member 50 is shown from multiple perspectives in FIGS. 8-11 in order to better illustrate its complex shape. For example, if a rectangular box were drawn around the tubular member, the box would have a significant amount of volume in order to accommodate the entire shape of the part.

As shown in the figures, the tubular member 50 includes linear sections 52, 54, 56, 58 and 60. In addition, the tubular member 50 includes curved sections 62, 64, 66 and 68. Curved section 62 is positioned inbetween linear section 52 and linear section 54. Curved section 64 is positioned inbetween linear section 54 and linear section 56. Curved section 66, on the other hand is positioned inbetween linear section 56 and linear section 58. Finally, curved section 68 is positioned inbetween linear section 58 and linear section 60.

Each curved section in the tubular member creates an angular displacement. The curved sections may lie in a single plane or may lie in multiple planes (based on the axis of the tubular member such that the axis lies in each plane).

As shown in the figures, the tubular member defines a passageway 70. The passageway 70 is for conveying fluids. In particular, the passageway 70 extends from a first end or opening 72 to a second end or opening 74. As described above, the tubular member is particularly well suited for use in environments where the part is subjected to high temperatures.

Referring particularly to FIGS. 9-11, the angular displacements that are created by the curved sections are shown in greater detail. In various embodiments of the present disclosure, tubular members can be produced having multiple curved sections creating multiple angular displacements with extreme angles, such as angles varying from about 60° to about 120°, such as from about 70° to about 110°, such as from about 80° to about 100°. In the embodiment illustrated in FIGS. 9-11, for instance, the tubular member 50 includes three such curved sections. It should be understood, however, that the tubular member may include further curved sections containing further extreme angles.

Referring to the curved sections contained in the tubular member 50, FIGS. 8 and 9 best illustrate curved section 62. As shown, this curved section results in an angular displacement of the tubular member of about 900. The angular displacement of curved section 62 lies in a single plane. The curved section 62 may be described as a 90° elbow.

Curved section 64 of the tubular member 50 is more complex than the curved section 62. Curved section 64 is shown from multiple views in FIGS. 9-11. In fact, curved section 64 includes multiple angular displacements that lie in different planes. For instance, as shown in FIG. 11, curved section 64 includes a first angular displacement 80 that is somewhat gradual. In particular, angular displacement 80 is from about 5° to about 20° when measured in reference to the axis of the tubular member. As shown in FIG. 9, curved section 64 also includes more of an extreme angular displacement. For instance, as shown in FIGS. 9 and 10, curved section 64 includes an angular displacement 82 that is from about 70° to about 110°, and particularly from about 80° to about 100° and lies in a different plane than angular displacement 80. Angular displacement 82, for instance, is shown in FIG. 10 where linear section 56 forms approximately a 90° angle with linear section 54.

In addition to the angular displacement 82, curved section 64 further includes an angular displacement 84 that is in a different plane than the angular displacement 82. Referring to FIG. 10, for instance, curved section 64 not only forms the angular displacement 82 but also simultaneously forms an angular displacement 84 that lies in a plane that intersects with the plane in which angular displacement 82 lies. Angular displacement 84 is approximately from about 300 to about 70° in relation to the axis of the tubular member 50.

Referring to FIGS. 10 and 11, the tubular member 50 further includes a curved section 66. The curved section 66, while only creating small angular displacements, does so in multiple planes. For instance, as shown in FIG. 10, curved section 66 creates an angular displacement 88 that appears in a first plane. As shown in FIG. 11, the curved section 66 also produces an angular displacement 90 that lies in a different plane. Thus, although the angular displacements are not extreme, the parison used to form the tubular member 50 must be manipulated in different directions in order to produce the curved section 66.

The tubular member 50 further includes the curved section 68 as shown in FIGS. 9, 10 and 11. The curved section 68 also produces multiple angular displacements in different planes. As shown in FIGS. 10 and 11, for instance, the curved section 68 produces an angular displacement 92 of approximately 90° in a first plane. As shown in FIGS. 9, the curved section 68 also produces a second angular displacement in a different plane, specifically a second plane that intersects the first plane. As shown in FIG. 9, the second angular displacement is at least about 50°, such as from about 50° to about 80°.

As described above, the tubular members of the present disclosure comprise one-piece molded parts made from a polymer composition containing a polymer with a relatively high melting temperature. The polymer contained in the polymer composition, for instance, has a melting point greater than about 280° C., such as greater than about 285° C., such as greater than about 290° C., such as greater than about 295° C., such as even greater than about 300° C. In general, the melting point of the thermoplastic polymer is less than about 340° C. Polymer compositions containing the above polymers are difficult to manipulate and mold, especially during blow molding processes in which tubular members are being formed that have a complex three-dimensional shape.

In accordance with the present disclosure, the polymer composition is formulated to have certain melt elongation characteristics.

The high temperature polymer present in the polymer composition can vary depending upon the particular circumstances and the desired result. A non-exhaustive list of high temperature polymers that may be incorporated into the polymer composition include liquid crystal polymers, polyimide polymers, polyaryletherketone polymers, polyetherimide polymers, fluoropolymers, polyester polymers such as polycyclohexylene dimethyl terephthalate, polyphenylene sulfide polymers, and combinations thereof.

For instance, in one embodiment, the polymer composition may contain a liquid crystalline polymer. Suitable thermotropic liquid crystalline polymers may include instance, aromatic polyesters, aromatic poly(esteramides), aromatic poly(estercarbonates), aromatic polyamides, etc., and may likewise contain repeating units formed from one or more aromatic hydroxycarboxylic acids, aromatic dicarboxylic acids, aromatic diols, aromatic aminocarboxylic acids, aromatic amines, aromatic diamines, etc., as well as combinations thereof.

Aromatic polyesters, for instance, may be obtained from (1) two or more aromatic hydroxycarboxylic acids; (2) at least one aromatic hydroxycarboxylic acid, at least one aromatic dicarboxylic acid, and at least one aromatic diol; and/or (3) at least one aromatic dicarboxylic acid and at least one aromatic diol. Examples of suitable aromatic hydroxycarboxylic acids include, 4-hydroxybenzoic acid; 4-hydroxy-4′-biphenylcarboxylic acid; 2-hydroxy-6-naphthoic acid; 2-hydroxy-5-naphthoic acid; 3-hydroxy-2-naphthoic acid; 2-hydroxy-3-naphthoic acid; 4′-hydroxyphenyl-4-benzoic acid; 3′-hydroxyphenyl-4-benzoic acid; 4′-hydroxyphenyl-3-benzoic acid, etc., as well as alkyl, alkoxy, aryl and halogen substituents thereof. Examples of suitable aromatic dicarboxylic acids include terephthalic acid; isophthalic acid; 2,6-naphthalenedicarboxylic acid; diphenyl ether-4,4′-dicarboxylic acid; 1,6-naphthalenedicarboxylic acid; 2,7-naphthalenedicarboxylic acid; 4,4′-dicarboxybiphenyl; bis(4-carboxyphenyl)ether; bis(4-carboxyphenyl)butane; bis(4-carboxyphenyl)ethane; bis(3-carboxyphenyl)ether; bis(3-carboxyphenyl)ethane, etc., as well as alkyl, alkoxy, aryl and halogen substituents thereof. Examples of suitable aromatic diols include hydroquinone; resorcinol; 2,6-dihydroxynaphthalene; 2,7-dihydroxynaphthalene; 1,6-dihydroxynaphthalene; 4,4′-dihydroxybiphenyl; 3,3′-dihydroxybiphenyl; 3,4′-dihydroxybiphenyl; 4,4′-dihydroxybiphenyl ether; bis(4-hydroxyphenyl)ethane, etc., as well as alkyl, alkoxy, aryl and halogen substituents thereof. In one particular embodiment, the aromatic polyester is derived from 4-hydroxybenzoic acid and 2,6-hydroxynaphthoic acid. The monomer units derived from 4-hydroxybenzoic acid may constitute from about 45% to about 85% (e.g., 73%) of the polymer on a mole basis and the monomer units derived from 2,6-hydroxynaphthoic acid may constitute from about 15% to about 55% (e.g., 27%) of the polymer on a mole basis. The synthesis and structure of these and other aromatic polyesters may be described in more detail in U.S. Pat. Nos. 4,161,470; 4,473,682; 4,522,974; 4,375,530; 4,318,841; 4,256,624; 4,219,461; 4,083,829; 4,184,996; 4,279,803; 4,337,190; 4,355,134; 4,429,105; 4,393,191; 4,421,908; 4,434,262; and 5,541,240.

Liquid crystalline polyesteramides may likewise be obtained from (1) at least one aromatic hydroxycarboxylic acid and at least one aromatic aminocarboxylic acid; (2) at least one aromatic hydroxycarboxylic acid, at least one aromatic dicarboxylic acid, and at least one aromatic amine and/or diamine optionally having phenolic hydroxy groups; and (3) at least one aromatic dicarboxylic acid and at least one aromatic amine and/or diamine optionally having phenolic hydroxy groups. Suitable aromatic amines and diamines may include, for instance, 3-aminophenol; 4-aminophenol; 1,4-phenylenediamine; 1,3-phenylenediamine, etc., as well as alkyl, alkoxy, aryl and halogen substituents thereof. In one particular embodiment, the aromatic polyesteramide is derived from 2,6-hydroxynaphthoic acid, terephthalic acid, and 4-aminophenol. The monomer units derived from 2,6-hydroxynaphthoic acid may constitute from about 35% to about 85% of the polymer on a mole basis (e.g., 60%), the monomer units derived from terephthalic acid may constitute from about 5% to about 50% (e.g., 20%) of the polymer on a mole basis, and the monomer units derived from 4-aminophenol may constitute from about 5% to about 50% (e.g., 20%) of the polymer on a mole basis. In another embodiment, the aromatic polyesteramide contains monomer units derived from 2,6-hydroxynaphthoic acid, and 4-hydroxybenzoic acid, and 4-aminophenol, as well as other optional monomers (e.g., 4,4′-dihydroxybiphenyl and/or terephthalic acid). The synthesis and structure of these and other aromatic poly(esteramides) may be described in more detail in U.S. Pat. Nos. 4,339,375; 4,355,132; 4,351,917; 4,330,457; 4,351,918; and 5,204,443.

In another embodiment, the polymer composition may contain a polyarylene sulfide polymer. In one particular embodiment, the polymer composition may contain a linear polyarylene sulfide resin combined with a branched polyarylene sulfide resin. The linear polyarylene sulfide resin that may be used in the composition of the present disclosure can vary depending upon the particular application and the desired results. Polyarylene sulfide resins that may be used are comprised of repeating units represented by the formula —(—Ar—S—)—, wherein Ar is an arylene group.

Examples of arylene groups that can be present in the linear polyarylene sulfide resin include p-phenylene, m-phenylene, o-phenylene and substituted phenylene groups (wherein the substituent is an alkyl group preferably having 1 to 5 carbon atoms or a phenyl group), p,p′-diphenylene sulfone, p,p′-biphenylene, p,p′-diphenylene ether, p,p′-diphenylenecarbonyl and naphthalene groups.

Polyarylene sulfides that may be used, in one embodiment, include polyarylene thioethers containing repeat units of the formula:

—[(Ar¹)_(n)—X]_(m)—[(Ar²)_(i)—Y]_(j)—(Ar³)_(k)—Z]_(l)—[(Ar⁴)_(o)—W]_(p)—

wherein Ar¹, Ar², Ar³, and Ar⁴ are the same or different and are arylene units of 6 to 18 carbon atoms; W, X, Y, and Z are the same or different and are bivalent linking groups selected from —SO₂—, —S—, —SO—, —CO—, —O—, —COO— or alkylene or alkylidene groups of 1 to 6 carbon atoms and wherein at least one of the linking groups is —S—; and n, m, i, j, k, l, o, and p are independently zero or 1, 2, 3, or 4, subject to the proviso that their sum total is not less than 2. The arylene units Ar¹, Ar², Ar³, and Ar⁴ may be selectively substituted or unsubstituted. Arylene units include phenylene, biphenylene, naphthylene, anthracene and phenanthrene. The polyarylene sulfide can include at least 30 mole percent, particularly at least 50 mole percent and more particularly at least 70 mole percent arylene sulfide (—S—) units. The polyarylene sulfide polymer can include at least 85 mole percent sulfide linkages attached directly to two aromatic rings.

In one embodiment, the linear polyarylene sulfide polymer is polyphenylene sulfide (PPS), defined herein as containing the phenylene sulfide structure —(C₆H₄—S)_(n)— (wherein n is an integer of 1 or more) as a component thereof.

Polyphenylene sulfide resins are considered to have a high degree of linearity in cases where they exhibit a complex melt viscosity of less than 13,000 poise at 310° C. and 0.1 rad/sec. It is preferred for polyphenylene sulfide resins having a high degree of linearity to exhibit a complex melt viscosity of less than 13,000 poise at 310° C. and 0.1 rad/sec. For purposes of this invention the melt viscosity of the polyphenylene sulfide resin can be determined with an ARES® strain-controlled rheometer (from TA Instruments) operated in dynamic (oscillatory) shear mode using parallel plate geometry with 25 mm disks and a frequency of 0.1 rad/sec at 310° C. For a PPS having a high degree of linearity as defined above per the ARES® rheometer, the corresponding melt viscosity as measured in a capillary rheometer at 310° C., 1200 l/s shear rate will be preferably below 6500 poise.

Synthesis techniques that can be used in making linear polyphenylene sulfide resins that are suitable for utilization in the practice of this invention are described in U.S. Pat. No. 4,814,430, U.S. Pat. No. 4,889,893, U.S. Pat. No. 5,380,783, and U.S. Pat. No. 5,840,830, the teachings of which are incorporated herein by reference in their entirety.

The linear polyarylene sulfide polymer selected for use in the composition of the present disclosure can depend on various factors. For instance, in general a linear polyarylene sulfide polymer should be chosen that is compatible with the molding process, such as a blow molding process, and is compatible with the other components contained in the composition. In general, for instance, the linear polyarylene sulfide polymer can have a melt viscosity of from about 20 Pa·s to about 500 Pa·s (from about 200 poise to about 5,000 poise). As used herein, melt viscosity of the linear polyarylene sulfide polymer is determined in accordance with the ASTM Test No. 1238-70 at 316° C. and at 1200 s⁻¹.

A linear polyarylene sulfide polymer selected for use in the present disclosure may also have a relatively low chlorine content. In general, lower melt viscosity polymers generally have a greater chlorine content. Thus, a balance may be struck between selecting a polymer having an appropriate melt viscosity while also selecting a polymer that has a low chlorine content. In one embodiment, the linear polyarylene sulfide polymer may have a chlorine content of less than about 2000 parts per million for generating a composition with a chlorine content of less than 900 parts per million.

Linear polyarylene sulfide polymers that may be used in the present disclosure are available from numerous commercial sources. In one embodiment, for instance, polymers can be purchased from Ticona LLC and/or the Celanese Corporation under the trade name FORTRON®.

In one embodiment, a linear polyarylene sulfide polymer having a relatively high melt viscosity can be combined with a linear polyarylene sulfide polymer having a relatively low melt viscosity for producing a PPS polymer having the desired characteristics.

In addition to a linear polyarylene sulfide polymer, the composition of the present disclosure also contains a branched polyarylene sulfide polymer, particularly a relatively high molecular weight branched polyphenylene sulfide polymer.

The branched polyarylene sulfide polymer may have a branched structure obtained by polymerizing a sulfur compound and a dihalo-aromatic compound in the presence of a polyhalo-aromatic compound having 3 or more halogen substituents.

The dihalo-aromatic compound used may be a dihalogenated aromatic compound having 2 halogen atoms directly bonded to the aromatic ring. Specific examples of the dihalo-aromatic compound include o-dihalobenzenes, m-dihalobenzenes, p-dihalobenzenes, dihalotoluenes, dihalonaphthalenes, methoxy-dihalobenzenes, dihalobiphenyls, dihalobenzoic acids, dihalodiphenyl ethers, dihalodiphenyl sulfones, dihalodiphenyl sulfoxides and dihalodiphenyl ketones. These dihalo-aromatic compounds may be used either singly or in any combination thereof.

The halogen atom can be fluorine, chlorine, bromine and iodine, and 2 halogen atoms in the same dihalo-aromatic compound may be the same or different from each other. In many cases, o-dichlorobenzene, m-dichlorobenzene, p-dichlorobenzene or a mixture of 2 or more compounds thereof is used as the dihalo-aromatic compound.

The polyhalo-aromatic compound having 3 or more halogen substituents is used for introducing a branched structure into the polyphenylene sulfide resin. A halogen substituent is generally a halogen atom directly bonded to the aromatic ring. The halogen atom can be fluorine, chlorine, bromine and iodine, and plural halogen atoms in the same dihalo-aromatic compound may be the same or different from each other.

Specific examples of the polyhalo-aromatic compound include 1,2,3-trichlorobenzene, 1,2,4-trichlorobenzene, 1,3,5-trichlorobenzene, hexachlorobenzene, 1,2,3,4-tetrachlorobenzene, 1,2,4,5-tetrachlorobenzene, 1,3,5-trichloro-2,4,6-trimethylbenzene, 2,4,6-trichlorotoluene, 1,2,3-trichloronaphthalene, 1,2,4-trichloronaphthalene, 1,2,3,4-tetrachloronaphthalene, 2,2′,4,4′-tetrachlorobiphenyl, 2,2′,4,4′-tetrachlorobenzophenone and 2,4,2′-trichlorobenzophenone.

These polyhalo-aromatic compounds may be used either singly or in any combination thereof. Among the polyhalo-aromatic compounds, trihalobenzenes such as 1,2,4-trichlorobenzene and 1,3,5-trichlorobenzene are preferred, and trichlorobenzenes are more preferred.

In one embodiment, branching may be achieved by copolymerizing with a trifunctional monomer such as trichlorobenzene in a molar weight proportion of 0.3 to 8%, such as from about 1% to about 5%. Branching may be obtained by first obtaining a linear polymer with the difunctional monomer which is then solid stated to a higher molecular weight by heating the polymer in air or air/nitrogen mixture and at temperatures between the glass transition temperature (80° C.) and melting point transition (275° C.) for an extended time. When high level of branching is achieved, the viscosity of the polyphenylene sulfide may be very high.

One process for producing branched polyarylene sulfide resins comprises (1) an initial-stage polymerization step (A) of reacting an alkali metal sulfide, a dihaloaromatic compound (hereinafter referred to as “DHA”) and a polyhaloaromatic compound which has more than two halogen substituents in a molecule (hereinafter referred to as “PHA”), in an organic amide solvent under the presence of water in an amount of 0.5 to 2.9 moles per mol of said alkali metal sulfide, at a temperature in the range of 180° to 235° C. until a total conversion of DHA and PHA reaches 50 to 98% and a melt viscosity of a polyarylene sulfide obtained at the end of the step, becomes 5 to 5,000 poise measured at 310° C. and a shear rate of 1,200/second; (2) a temperature raising step (B) in which while adjusting the amount of water to be 2.5 to 7 moles per mol of the fed alkali metal sulfide, a temperature raising condition of the reaction mixture until it reaches to 240° C. is controlled so that the melt viscosity of the prepolymer obtained at 240° C., is 300 to 10,000 poise, measured at 310° C. and a shear rate of 1,200/second, and the temperature raising condition between 240° C. and the reaction temperature of the next step (C) is further controlled to be within the range of 10° to 100° C./hour; and (3) a second-stage polymerization step (C) for further reacting the reaction mixture at a temperature in the range of 245° to 290° C. until the melt viscosity of the final polymer becomes 100,000 poise or more as measured at 330° C. and a shear rate of 2/second.

In general, the branched polyarylene sulfide resin may have a melt viscosity of from about 100,000 Pa·s to about 300,000 Pa·s when measured at a temperature of 330° C. and at a shear rate of 2 sec⁻¹. The average molecular weight of the polyarylene sulfide resin, in one embodiment, is from about 15,000 to about 40,000, such as from about 22,000 to about 30,000 gram/mol. The number average molecular weight of the polymer can be from about 3,000 to about 10,000, such as from about 4,500 to about 9,000 gram/mol.

In general, the polyarylene sulfide resins are present in the composition in an amount greater than about 35% by weight. For instance, the polyarylene sulfide resins may be present in an amount greater than about 50% by weight, such as in an amount greater than 60% by weight, such as in an amount greater than 70% by weight. The polyarylene sulfide resins are generally present in an amount less than about 95% by weight, such as in an amount less than about 90% by weight.

The relative proportions of the branched polyarylene sulfide resin in relation to the linear polyarylene sulfide resin can vary depending upon various factors. The factors include the other components contained in the composition and the desired properties that are to be obtained. In general, the weight ratio between the branched polyarylene sulfide resin and the linear polyarylene sulfide resin is generally from about 1:5 to about 1:60, such as from about 1:20 to about 1:50, such as from about 1:30 to about 1:40.

In one embodiment, the composition of the present disclosure contains the linear polyphenylene sulfide resin in an amount from about 50% to about 90% by weight, such as in an amount from about 60% to about 80% by weight. The branched polyphenylene sulfide resin, on the other hand, may be present in the composition in an amount from about 0.5% to about 30% by weight, such as in an amount from about 1% to about 15% by weight.

In general, the combination of a linear polyarylene sulfide resin with a branched polyarylene sulfide resin has been found to dramatically increase the low shear rate storage modulus of the composition. In accordance with the present disclosure, various other components may be contained in the composition either alone or in combination with the polyarylene sulfide resins in order to further improve the stress-strain characteristics, melt viscosity characteristics, shear rate storage modulus characteristics, or other characteristics and properties that either relate to the polymer when in a fluid state or to the final article produced during the molding process.

In one embodiment, for instance, the polymeric composition further contains a polyphenylene oxide in combination with a compatibilizer.

The polyphenylene oxide polymer, for instance, may comprise a thermoplastic, linear, noncrystalline polyether. The polyphenylene oxide polymer may provide various advantages and benefits to the overall composition. In one embodiment, for instance, the polyphenylene oxide polymer may be included in the composition in order to increase heat stability.

Polyphenylene oxides can be prepared by a variety of processes, such as by the thermal decomposition of 3,5-dibromobenzene-1,4-diazooxide, the oxidation of halogenated phenols, through a condensation reaction, and the refluxing of potassium or silver halogenated phenates in benzophenone.

In one embodiment, the polyphenylene oxide polymer may have recurring units of the formula:

wherein R and R′ may be the same or different and are hydrogen atoms, halogen atoms, substituted and unsubstituted hydrocarbon groups, halohydrocarbons, alkoxy groups or phenoxy groups. For example, R and R′ can be CH₃, CH₂CH₃, isopropyl, CH₃O, CH₂C₆H₅, Cl, and C₆H₅. Preferably, R and R′ are hydrocarbon groups of from one to eight carbon atoms, including aliphatic, cycloaliphatic and aromatic groups. Most preferably, R and R′ are the same.

One polyphenylene oxide that may be used is poly (2,6-dimethyl-1,4-phenylene oxide).

When present, the polyphenylene oxide can generally be contained in the composition in an amount from about 3% to about 50% by weight, such as in an amount from about 10% to about 30% by weight.

In addition to or instead of a polyphenylene oxide, the composition may contain other polymers. Other polymers may include, for instance, high temperature polyamides (melting temperature greater than 270° C., such as greater than 300° C.), a liquid crystal polymer such as an aromatic polyester polymer, a polyethyleneimine polymer, or the like. The above polymers can be present alone or in combination with other polymers in the weight percentages described above.

The polymer composition can also contain a compatibilizer. The compatibilizer can be present to provide strengthening of the interphase between the polyarylene sulfide and other components. In some embodiments the compatibilizer can be a graftlinking additive such as those illustrated below as (i), (ii) and (iii), wherein:

(i) has the structure:

wherein R and R¹ can be the same or different and represent a monovalent alkyl, alkenyl, alkynyl, aralkyl, aryl or alkaryl group of 1 to 20 carbon atoms, or an ether substituted derivative thereof, or a halogen, wherein R² represents a monovalent alkyl, alkenyl, alkynyl, aralkyl, aryl or alkaryl group of 1 to 20 carbon atoms, or an ether substituted derivative thereof, or an oxy derivative or an ether substituted oxy derivative thereof or a halogen, wherein A, B and C represent a monovalent aroxy group, a thioaroxy group, a diester phosphate group, a diester pyrophosphate group, a oxyalkylamino group, a sulfonyl group, or a carboxyl group, wherein a, b, and c represent integers, and wherein the sum of a, b, and c is 3;

(ii) has the structure:

(R¹—O—)_(y)—X—(—O—R²—W)_(z)

wherein each R¹ represents an alkyl radicals having from 1 to 8 carbon atoms, wherein R² represents a divalent radical selected from the group consisting of alkylenes having 1 to 15 carbon atoms, arylene and alkyl substituted arylene groups having 6 to 10 carbon atoms, wherein W represents an epoxy group; wherein y represents an integer of from 1 to 3, wherein z represents an integer from 1 to 3, wherein the sum of y and z equals 4, and wherein X represents titanium or zirconium; and

(iii) has the structure:

Z-Alk-S_(n)-Alk-Z  (I)

in which Z is selected from the group consisting of

where R¹ is an alkyl group of 1 to 4 carbon atoms, cyclohexyl or phenyl; wherein R² is alkoxy of 1 to 8 carbon atoms, or cycloalkoxy of 5 to 8 carbon atoms; and wherein Alk is a divalent hydrocarbon of 1 to 18 carbon atoms and n is an integer of 2 to 8.

Compounds of the type (iii) as compatibilizers are disclosed in U.S. Pat. No. 5,149,731, the teachings of which are incorporated herein by reference in their entirety.

The preferred compatibilizers are alkoxysilane compounds or organosilane compounds selected from the group consisting of a vinlyalkoxysilanes, epoxyalkoxysilanes, aminoalkoxysilanes, and mercaptoalkoxysilanes. Examples of the vinylalkoxysilane that can be utilized include vinyltriethoxysilane, vinyltrimethoxysilane and vinyltris(β-methoxyethoxy)silane. Examples of the epoxyalkoxysilanes that can be used include γ-glycidoxypropyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane and γ-glycidoxypropyltriethoxysilane. Examples of the mercaptoalkoxysilanes that can be employed include γ-mercaptopropyltrimethoxysilane and γ-mercaptopropyltriethoxysilane.

Amino silanes are a preferred class of alkoxy silanes that can be used in the practice of compatibilizing polyarylene sulfide and other components and are typically of the formula: R¹—Si—(R²)₃, wherein R¹ is selected from the group consisting of an amino group such as NH₂; an aminoalkyl of from about 1 to about 10 carbon atoms, preferably from about 2 to about 5 carbon atoms, such as aminomethyl, aminoethyl, aminopropyl, aminobutyl, and the like; an alkene of from about 2 to about 10 carbon atoms, preferably from about 2 to about 5 carbon atoms, such as ethylene, propylene, butylene, and the like; and an alkyne of from about 2 to about 10 carbon atoms, preferably from about 2 to about 5 carbon atoms, such as ethyne, propyne, butyne and the like; and wherein R² is an alkoxy group of from about 1 to about 10 atoms, preferably from about 2 to about 5 carbon atoms, such as methoxy, ethoxy, propoxy, and the like. In a preferred embodiment, in the amino silane compound of the R¹—Si—(R²)₃, R¹ is selected from the group consisting of aminomethyl, aminoethyl, aminopropyl, ethylene, ethyne, propylene and propyne, and R² is selected from the group consisting of methoxy groups, ethoxy groups, and propoxy groups.

It is typically preferred for the amino silane compound to be of the formula:

R³—Si—(R⁴)₃ wherein R³ is an amino group such as NH₂ or an aminoalkyl of from about 1 to about 10 carbon atoms such as aminomethyl, aminoethyl, aminopropyl, aminobutyl, and the like, and wherein R⁴ is an alkoxy group of from about 1 to about 10 atoms, such as methoxy groups, ethoxy groups, propoxy groups, and the like. It is also preferred for the amino silane to be of the formula: R⁵—Si—(R⁶)₃ wherein R⁵ is selected from the group consisting of an alkene of from about 2 to about 10 carbon atoms such as ethylene, propylene, butylene, and the like, and an alkyne of from about 2 to about 10 carbon atoms such as ethyne, propyne, butyne and the like, and wherein R⁶ is an alkoxy group of from about 1 to about 10 atoms, such as methoxy group, ethoxy group, propoxy group, and the like. The amino silane can be a mixture of various compounds of the formula R¹—Si—(R²)₃, R³—Si—(R⁴)₃, and R⁵—Si—(R⁶)₃.

Some representative amino silanes that can be used include aminopropyl triethoxy silane, aminoethyl triethoxy silane, aminopropyl trimethoxy silane, aminoethyl trimethoxy silane, ethylene trimethoxy silane, ethylene triethoxy silane, ethyne trimethoxy silane, ethyne triethoxy silane, aminoethylaminopropyltrimethoxy silane, 3-aminopropyl triethoxy silane, 3-aminopropyl trimethoxy silane, 3-aminopropyl methyl dimethoxysilane or 3-aminopropyl methyl diethoxy silane, N-(2-aminoethyl)-3-aminopropyl trimethoxy silane, N-methyl-3-aminopropyl trimethoxy silane, N-phenyl-3-aminopropyl trimethoxy silane, bis(3-aminopropyl) tetramethoxy silane, bis(3-aminopropyl) tetraethoxy disiloxane, and combinations thereof. The amino silane can also be an aminoalkoxysilane, such as γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, γ-aminopropylmethyldimethoxysilane, γ-aminopropylmethyldiethoxysilane, N-(β-aminoethyl)-γ-aminopropyltrimethoxysilane, N-phenyl-γ-aminopropyltrimethoxysilane, γ-diallylaminopropyltrimethoxysilane and γ-diallylaminopropyltrimethoxysilane. A highly preferred amino silane is 3-aminopropyltriethoxysilane which is available from Degussa, Sigma Chemical Company, and Aldrich Chemical Company.

In other embodiments, the compatibilizer may be provided by a modified polyphenylene ether, such as an epoxy triazine capped polyphenylene ether as disclosed in Han et al., U.S. Pat. No. 5,122,578, which is incorporated herein by reference. Another end-cap for PPO is epoxy chlorotriazine. Yet another compatibilizer is disclosed in Khouri et al., U.S. Pat. No. 5,132,373 such as an ortho ester capped poly(phenylene ether). Khouri et al., U.S. Pat. No. 5,212,255 sets out ortho ester grafted poly(phenylene ether) resins and methods for preparation thereof, and is incorporated herein by reference.

In yet further embodiments, the compatibilization of polyarylene sulfide with other components can be provided by a modified polyarylene sulfide polymer which contains functional groups which may include, but are not limited to, amino, carboxylic acid, metal carboxylate, disulfide, thio and metal thiolate groups. A method for incorporation of functional groups into PPS can be found in U.S. Pat. No. 4,769,424, incorporated herein by reference, which discloses incorporation of substituted thiophenols into halogen substituted PPS. Another method involves incorporation of chlorosubstituted aromatic compounds containing the desired functionality reacted with an alkali metal sulfide and chloroaromatic compounds. A third method involves reaction of PPS with a disulfide containing the desired functional groups, typically in the melt or in a suitable high boiling solvent such as chloronaphthalene.

In one embodiment, the polymeric composition further contains a viscosity stabilizer, such as a polytetrafluoroethylene polymer. When present, the polytetrafluoroethylene polymer has a tendency to make the viscosity of the composition during extrusion more uniform. In particular, the polytetrafluorethylene polymer inhibits the formation of small domains of low viscosity areas during melt processing that can lead to irregularities in the finished product, such as non-uniform wall thicknesses.

Polytetrafluoroethylene is commonly known by the federally registered trademark TEFLON which is the name for compounds marketed by E. I. DuPont de Nemours Co., Inc.; FLUON which is the name for compounds marketed by ICI Americas; and WHITCON 2 which is the name of a particulate powder marketed by ICI Americas. Such materials are recognized for heat resistance and friction-reduction as when used, for example, on the surfaces of kitchen utensils and for other mechanical applications. Such materials are available in various forms. This more common form of particulate PTFE is manufactured by grinding or fracturing larger PTFE particles into powdered particulate PTFE.

In general, the polytetrafluoroethylene polymer may be present in the composition in an amount from about 0.01% to about 5% by weight, such as in an amount from about 0.1% to about 2% by weight. In one particular embodiment, the polytetrafluoroethylene polymer has a specific gravity of from about 2.0 g/cm³ to about 2.3 g/cm³, such as from about 2.1 g/cm³ to about 2.2 g/cm³. In one particular embodiment, the polytetrafluoroethylene polymer has a specific gravity of about 2.15 g/cm³.

The polymeric composition can also contain a reinforcing agent, such as reinforcing fibers or mineral fillers. In one embodiment, for instance, the resin composition may contain glass reinforcing fibers. Any suitable glass fibers may be included in the composition. In one embodiment, for instance, the fibers may be comprised of lime-aluminum borosilicate glass.

Other reinforcing fibers that may be used in accordance with the present disclosure include carbon fibers, metal fibers, aromatic polyamide fibers, rockwool fibers, shape memory alloy fibers, boron fibers, poly(p-phenylene-2,6-benzobisoxazole) fibers, and mixtures thereof. Carbon fibers that may be used include amorphous carbon fibers, graphitic carbon fibers, or metal-coated carbon fibers. Metal fibers may include stainless steel fibers, aluminum fibers, titanium fibers, magnesium fibers, tungsten fibers, and the like.

Fiber diameters can vary depending upon the particular fiber used and are available in either chopped or continuous form. The reinforcing fibers, for instance, can have a diameter of less than about 100 microns, such as less than about 50 microns. For instance, chopped or continuous fibers can have a fiber diameter of from about 5 microns to about 50 microns, such as from about 5 microns to about 15 microns. If desired, the fibers may be pretreated with a sizing that may also facilitate mixing with the polymer. Fiber lengths can be controlled by one skilled in the art during compounding varying compounding conditions (e.g. temperature profile, rate and shear or screw speed) and screw design (control intensity of mixing) used to mix and/or disperse the fiber in the polymeric composition. In one embodiment, for instance, the fibers can have an initial length of from about 3 mm to about 5 mm while the final length after compounding could vary from 100 microns to 1500 microns depending on choice of compounding conditions and screw design used in compounding.

The reinforcing fibers can be present within the resulting article in an amount from about 10% to about 50% by weight, such as from about 10% to about 25% by weight.

Suitable mineral fillers that may be included in the resin composition include talc, clay, silica, calcium silicate, calcium sulfate, barium sulfate, mica, calcium carbonate, titanium dioxide, mixtures thereof, and the like. The fillers may be present in the composition in the amount from about 0.5% to about 30% by weight, such as from about 5% to about 25% by weight.

In addition to the polyarylene sulfide polymers and other components described above, the composition of the present disclosure can further contain an impact modifier.

In one embodiment, an impact modifier is selected that is chemically reactive with the compatibilizer. In one embodiment, for instance, the impact modifier may comprise a random copolymer of a polyolefin and glycidyl methacrylate. For instance, in one embodiment, the impact modifier may comprise a random copolymer of polyethylene and glycidyl methacrylate. The amount of glycidyl methacrylate contained in the random copolymer may vary. In one particular embodiment, the random copolymer contains the glycidyl methacrylate in an amount from about 6% to about 10% by weight.

The above impact modifier may combine with an organosilane compatibilizer and the polyphenylene sulfide resins so as to raise the low shear viscosity, melt elongation, and melt strength of the composition. Thus, in one embodiment, the impact modifier is present in the composition in an amount from about 0.5% to about 10% by weight.

Fiber reinforced polymeric compositions as described above possess an optimal combination of properties. Compositions formulated in accordance with the present disclosure have a relatively high near zero shear rate melt strength and engineering stress at a high percent strain, but yet still have a processable high shear rate melt viscosity. The above combination of properties allows the thermoplastic material to hold its shape at close to melt temperature, which becomes very important in processes for blow molding parts with complex shapes.

Having a high melt viscosity and a high low shear rate storage modulus, for instance, provides better control of the polymer during extrusion or molding of the parison. For instance, the composition of the present disclosure enables extrusion blow molding of articles with uniform wall thickness and smooth interior surfaces. In addition, the polymeric composition allows for high extrusion rates. Further, having a high engineering stress at a high percent strain enhances the ability to achieve complex three-dimensional manipulation processing of the parison. Due to the improved processability of the composition, the composition leads to higher throughput at a lower scrap rate than a comparative product.

Example

Various compositions (samples 1-8) were formulated in accordance with the present disclosure. The compositions contained a linear polyphenylene sulfide resin combined with a branched polyphenylene sulfide resin. A comparative composition (1115L0) was also formulated that only contained a linear polyphenylene sulfide resin. As shown in FIG. 7, stress strain curves were plotted for the comparative sample as well as samples 1-8 in order to determine the engineering stress at various percent elongations. The compositions were also tested for low shear rate storage modulus, melt viscosity, and tensile strength. These data are summarized in the chart below.

The compositions were made with the following components.

-   -   1. A linear polyphenylene sulfide resin having a melt viscosity         of 140 Pa·s measured at 1200 s⁻¹ at 316° C.     -   2. A branched polyphenylene sulfide resin.     -   3. Glass fibers having an average diameter of 10 microns.     -   4. A polytetrafluoroethylene powder which had a specific gravity         of 2.15 g/cm³.     -   5. An aminosilane coupling agent which was product number         KBE-903 commercially available from the Shin-Etsu Chemical         Company.     -   6. An impact modifier that comprised a random copolymer of         ethylene and glycidyl methacrylate wherein the glycidyl         methacrylate content was 8% by weight.     -   7. A polymer lubricant obtained from Lonza, Inc. under the name         GLYCOLUBE, which is a pentaerythritol tetrastearate.     -   8. Color pigment.

The following results were obtained:

Comparative Sample Sample Sample Sample Sample Sample Sample Sample (1115L0) No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 Linear Polyphenylene 81.6 74.3 74.3 77.7 65.9 69.3 76.9 66.7 69.3 Sulfide Branched Polyphenylene 2 2 2 10 10 2 10 10 Sulfide Glass Fibers 15 15 15 15 15 15 15 15 15 Aminosilane (Compatibilizer) 0.6 0.3 0.7 0.3 0.7 0.3 0.7 0.3 0.7 Lubricant 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 Color pigment 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 Impact Modifier 5 5 2 5 2 2 5 2 PTFE 0.6 0.2 0.2 0.6 0.6 0.6 0.2 0.2 Engineering stress (kPa) @ 437 117 193 85 153 257 465 165 100% strain @ 300° C., 5 s⁻¹ Engineering stress (kPa) @ 325 374 332 215 234 437 426 427 628 40% strain @ 300° C., 5 s⁻¹ Maximum engineering stress 467/115 392/42 351/48 224/42 246/42 481/48 585/74 467/48 683/48 (kPa) and corresponding % strain @ 300° C., 5 s⁻¹ Low Shear Rate Storage 1000 1920 3025 568 12519 2458 1834 2403 5318 Modulus (G′) (Pa) @ 0.1 rad/sec, 310° C. Melt Viscosity (Kpoise) @ 5.50 5.51 10.01 4.02 11.63 5.69 6.75 6.58 10.37 316° C., 400 s⁻¹ Tensile strength (MPa) 136.00 112.45 112.12 115.68 114.29 123.77 124.56 114.19 123.95

Referring to FIG. 7, a stress-strain curve at 300° C., 5 s⁻¹ is shown. The composition can also exhibit certain traits on a stress-strain curve at 300° C., 5 s⁻¹, as shown in detail in FIG. 7. The stress-strain curve is determined through uniaxial tensile testing of a specimen and shows the engineering stress (Pa) on the γ-axis plotted against the percent strain (%) on the x-axis. The test specimens used in obtaining the data for FIG. 7 were approximately 10 mm wide by 30 mm long and had a thickness of about 0.8 mm. Test specimens can be obtained by compression or injection molding and can then be tested on an instrument such as a TA ARES with EVF (extensional viscosity fixture) at preset temperature and elongation rates to determine each specimen's stress-strain curve.

The stress-strain curve graphically represents the relationship between the stress, which is derived from measuring the load applied on the sample, and the strain, which is derived from measuring the deformation of a sample, i.e. elongation, compression, or distortion. The test process involves placing a specimen of any of the compositions described herein in a mechanical testing apparatus and subjecting the sample to tension until the sample fractures. During the application of tension, the sample's elongation is recorded against the applied force. The data is manipulated so that it is not specific to the geometry of the test sample, and a resulting stress-strain curve can be plotted.

The elongation measurement is used to calculate the strain, E, using the following equation, which can be converted to percent strain by multiplying by 100:

$ɛ = {\frac{\Delta \; L}{L_{0}} = \frac{L - L_{0}}{L_{0}}}$

where ΔL is the change in gauge length, L₀ is the initial gauge length, and L is the final length. The force measurement is used to calculate the engineering stress, σ, using the following equation:

$\sigma = \frac{F_{n}}{A}$

where F is the force and A is the cross-sectional area of the sample or specimen. The tensile testing machine calculates the stress and strain as the force increases, so that the data points can be graphed into a stress-strain curve. For thermoplastic polymeric materials such as polyarylene sulfide polymer blends, the stress-strain curve typically includes an initial linear region that represents the elastic portion of the curve and a non-linear region that represents the plastic region of the curve. In the linear portion of the stress-strain curve, the stress is proportional to the strain. The elastic portion is the portion of the curve where the material will return to its original shape if the load is removed, while the plastic portion is the portion where some permanent deformation will occur, even if the load is removed. The point at which the linear (elastic) region of the curve ends and the non-linear (plastic deformation) region of the curve begins is known as the yield point. After the linear to non-linear transition point (the yield point or yield stress), the material undergoes yielding, where a slight increase in stress above the elastic limit will result in a breakdown of the material and cause it to deform permanently. The deformation that occurs here is called plastic deformation, and unlike with elastic loading, a load that causes yielding of the material will permanently change the material properties. During yielding, the material specimen will continue to elongate, as shown by an increase in the percent strain without any increase in stress, which is shown in FIG. 7 where the sample curves are flat immediately after the yield point. At this point, the material is referred to as perfectly plastic. For the samples in FIG. 7, the yielding behavior is minimal.

After yielding, the stress again increases with an increase in elongation, where when a further load is applied to the specimen, the resulting curve rises continuously but eventually becomes flatter as it reaches a maximum or ultimate engineering stress. At this point in the stress-strain curve, the material undergoes what is referred to as strain hardening. During this time, as the specimen is elongating, its cross-sectional area decreases uniformly over the specimen's entire length. After the maximum stress is reached, however, the cross-sectional area of the specimen begins to decrease in a localized region, as opposed to over the entire length of the specimen. This results in a region of constriction or necking in the specimen, and ultimately the specimen fractures, which is represented by the endpoints of the curves shown in FIG. 7.

Various formulations of materials exhibit different yield points, yielding regions, strain-hardening regions, maximum stresses, and necking regions, and without being bound by any particular theory the present inventors have found that polymeric compositions having particular yield points, strain hardening regions, maximum stresses, and necking regions characterized by particular ranges of stresses and percent strains exhibit improved processability in blow molding applications. For example, as shown in FIG. 7, the yield point for polymeric compositions that have been used in blow molding applications can occur at an engineering stress of from about 100 kPa to about 450 kPa and at a percent strain of from about 5% to about 25%, such as from about 150 kPa to about 300 kPa at a percent strain of from about 10% to about 20%. Additionally, strain hardening can occur over a range of engineering stresses, such as engineering stresses increasing from about 100 kPa to about 650 kPa over a range of percent strains of about 5% to about 90%, or such as engineering stresses increasing from about 200 kPa to about 600 kPa over a range of percent strains of from about 10% to about 80%. Further, the composition can have a relatively high maximum engineering stress even at relatively high percent strains. For example, the composition can exhibit a maximum engineering stress of from about 450 kPa to about 650 kPa at a percent strain of from about 60% to about 90% or from about 500 kPa to about 600 kPa at a percent strain of from about 70% to about 80%. Also, as shown in FIG. 7, necking can occur over a range of engineering stresses, such as engineering stresses decreasing from about 700 kPa to about 100 kPa over a range of percent strains of from about 60% to about 150%, or such as engineering stresses decreasing from about 600 kPa to about 175 kPa over a range o percent strains of from about 70% to about 120%.

Further, at a percent strain of about 100%, the composition can exhibit an engineering stress of from about 350 kPa to about 550 kPa. Moreover, at a percent strain of about 80%, the composition can exhibit an engineering stress of from about 450 kPa to about 650 kPa, and at a percent strain of 40%, the composition can exhibit an engineering stress of from about 350 kPa to about 550 kPa.

The synergistic effect of blending the components used to formulate compositions of the present disclosure enables significantly improved control during blow molding for producing products having controlled wall thickness with surface smoothness at relatively high extrusion rates.

As shown above and in FIG. 7, certain compositions formulated according to the present disclosure generally exhibited higher engineering stresses at higher percent elongations than the comparative 1115L0. By varying the percentages of certain components in the compositions, the inventors have found that some of the formulations, such as sample 6, demonstrated a higher melt viscosity, a higher low shear rate storage modulus, and a higher engineering stress than the comparative sample 1115L0, which can contributed to improved processability of the composition in molding applications.

In particular, sample 6 demonstrates improved processability in, for example, compared to the processability of comparative sample 1115L0. The inventors have found that the relationship between the engineering stress and the percent strain contributes to the improved processability over 1115L0.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims. 

What is claimed:
 1. An engine conduit for conveying fluids to or from an engine comprising: a single piece tubular member having a wall surrounding a hollow passageway, the tubular member being formed from a polymer composition, the polymer composition comprising a thermoplastic polymer having a melting point greater than about 280° C., the thermoplastic polymer being present in the polymer composition in an amount of at least about 40% by weight; and wherein the tubular member has a three-dimensional configuration including at least three linear sections separated by at least two angular displacements, the first angular displacement being from about 60° to about 120° when lying in a first plane, the second angular displacement also being from about 60° to about 120° and oriented such that the second angular displacement lies in a second plane that intersects with the first plane.
 2. An engine conduit as defined in claim 1, wherein the tubular member includes a curved section that defines the first angular displacement, the curved section also defining a third angular displacement that lies in a different plane than the first angular displacement.
 3. An engine conduit as defined in claim 1, wherein the tubular member includes at least three angular displacements, the third angular displacement also being from about 60° to about 120°.
 4. An engine conduit as defined in claim 1, wherein the wall has a wall thickness that is substantially uniform, the wall thickness varying by no more than 50%.
 5. An engine conduit as defined in claim 1, wherein the thermoplastic polymer has a melting point greater than about 290° C.
 6. An engine conduit as defined in claim 1, wherein the thermoplastic polymer comprises a liquid crystal polymer, a polyimide, a polyaryletherketone, a polyetherimide, a fluoropolymer, a polyester polymer, or combinations thereof.
 7. An engine conduit as defined in claim 1, wherein the thermoplastic polymer comprises a polyphenylene sulfide.
 8. An engine conduit as defined in claim 1, wherein the thermoplastic polymer comprises a polycyclohexylene dimethyl terephthalate.
 9. An engine conduit as defined in claim 1, wherein the polymer composition has a relatively high melt strength such that at 15° C. greater than the melting point of the thermoplastic polymer, the polymer composition displays an engineering stress of from about 350 kPa to about 550 kPa at 100% strain.
 10. An engine conduit as defined in claim 3, wherein the tubular member includes at least four angular displacements.
 11. An engine conduit as defined in claim 1, wherein the polymer composition further comprises a reinforcing agent.
 12. An engine conduit as defined in claim 11, wherein the reinforcing agent comprises a filler.
 13. An engine conduit as defined in claim 11, wherein the reinforcing agent comprises fibers.
 14. An engine conduit as defined in claim 1, wherein the first angular displacement and the second angular displacement are from about 80° to about 100°.
 15. An engine conduit as defined in claim 3, wherein the first angular displacement, the second angular displacement, and the third angular displacement are all from about 80° to about 100°.
 16. An engine connected to the engine conduit defined in claim
 1. 17. A single piece tubular member comprising a wall surrounding a hollow passageway, the tubular member being formed from a polymer composition, the polymer composition comprising a thermoplastic polymer having a melting point greater than about 280° C., the thermoplastic polymer being present in the polymer composition in an amount of at least 40% by weight, the tubular member having a three-dimensional configuration including at least four linear sections separated by at least three angular displacements, the first angular displacement being from about 60° to about 120° and lying in a first plane, the second angular displacement also being from about 60° to about 120° and lying in a second plane, the third angular displacement also being from about 60° to about 120° and lying in a third plane, the first plane, the second plane, and the third plane all being different and wherein two planes intersect the remaining plane.
 18. A tubular member as defined in claim 17, wherein the thermoplastic polymer comprises a liquid crystal polymer, a polyimide, a polyaryletherketone, a polyetherimide, a fluoropolymer, a polyester polymer, or combinations thereof.
 19. A tubular member as defined in claim 17, wherein the thermoplastic polymer comprises a polyphenylene sulfide.
 20. A tubular member as defined in claim 17, wherein the thermoplastic polymer comprises a polycyclohexylene dimethyl terephthalate.
 21. A tubular member as defined in claim 17, wherein the polymer composition has a relatively high melt strength such that at 15° greater than the melting point of the thermoplastic polymer, the polymer composition displays an engineering stress of from about 350 kPa to about 550 kPa at 100% strain. 